Time for a build thread....big turbo

S3Alex

Rarely neutral
Gold Supporter
A little bit of black hole shock....

A few months ago,the inlet looked like this.....




Then it got cleaned and looked like this......




Well....back to normal.....





And thats after only 5 months,with a catch can etc.

Clearly not as bad as the last time round,but still impressive.
 

S3Alex

Rarely neutral
Gold Supporter
:scared2:Progressing well.

Head's off,and being stripped down,with only the bolt for the hydraulic tensioner giving some serious resistance,so that's holding things up a bit.

New ARP bolts on the way,and obviously cam belt and chain being changed as well.


Something along these lines....




Then the fun can begin for Steve to put the valves in and make it all work.
 
Last edited:

s3_trev

Northern Ireland
Wow....is that catch can doing the slightest bit of good do you think?
 

S3Alex

Rarely neutral
Gold Supporter
Wow....is that catch can doing the slightest bit of good do you think?

The current one......not much I think.

The VTA system from Integrated Engineering should be a whole different ball game.
 

S3Alex

Rarely neutral
Gold Supporter
Steve has managed to sort that hydraulic tensioner bolt.......head off,and in bits now.

Good news is that the head,pistons,and stock valves are all in good condition,and no signs of any problems there,even after 500+bhp and 66 000 miles on the engine in total,with 30 000 since since the bottom end rebuild.

Apologies for the phone pic quality,but there are some better ones to follow from AMD.






Also seems that various companies (and I think APR included) have looked at porting the S3 head,and all came away thinking it to be of little benefit,although Integrated Engineering WILL do it,if you ask,but even they advised me that it wasn't needed or likely to help.
 

S3_Mat

Registered User
You getting a dyno run in Alex this time?
 

S3Alex

Rarely neutral
Gold Supporter
You getting a dyno run in Alex this time?

Hopefully.

It needs the timing and fuelling plus boost settings sorting out with the new cams so it may just need a little run.

The timing is going to be pushed a bit with the WMI and the maximum boost setting raised to 2.2bar.
 

S.

Save the manuals
and the shiny cover :D
 

S3Alex

Rarely neutral
Gold Supporter
AMD certainly have their work cut out with you fella :audibash:

I think they had enough trouble a couple of weeks ago with an APR turbo build that didnt quite fit,but nothing on mine has ever been easy!

The ATP turbo kit wasn't exactly RHD as billed,and needed a lot of work.
The ITG CAI didn't easily fit the turbo downpipe.
The Boulekos manifold needed a little trip to the grinder.
And so on.....:keule:

I have to hand it to Steve at AMD who never seems phased by all the little(or large )problems,and between the guys there,it just gets fixed every time.

If it was my place,I'd probably shut the doors every time the thing appears!
 

Dean_T

Registered User
To be fair though, a good workshop would welcome the challenge and they certainly have stepped up to the plate :)

Many, many times :jump::icon thumright:
 

S3Alex

Rarely neutral
Gold Supporter
To be fair though, a good workshop would welcome the challenge and they certainly have stepped up to the plate :)

Many, many times :jump::icon thumright:



I don't think they've shied away from anything that's actually practical.

And they know there's more after this......somewhere along the way,this thing needs it's extra injector rail hooking up....

 

Sevv

Pushing the limits..
looking Good Alex, as usual amazing progress.. cant wait to see dyno figures you really need them extra injectors as the car has more potential beyond that 550hp @ the crank mark... i think the porsche 911 injectors are a viable way forward for people without your manifold...
 

S3Alex

Rarely neutral
Gold Supporter
looking Good Alex, as usual amazing progress.. cant wait to see dyno figures you really need them extra injectors as the car has more potential beyond that 550hp @ the crank mark... i think the porsche 911 injectors are a viable way forward for people without your manifold...

Hi Sevv,

As always,it's being done incrementally....get the cams and cam cover plus breather done and running first,then back later for the extra injectors.

We want to see how far we can get on the RS4 injectors before hooking up the extra rail.
 

Sevv

Pushing the limits..
Hi Sevv,

As always,it's being done incrementally....get the cams and cam cover plus breather done and running first,then back later for the extra injectors.

We want to see how far we can get on the RS4 injectors before hooking up the extra rail.

would be wise im being told 550 is the most ill make with them injectors so ill be sourcing different injectors down the track.. tuning will always be an issue to be honest.., 8 injectors sounds complicated and you'll have more parts means more things prone to break... id hate to see the tuning side of things will be a challenge for sure....
 

s3_sid

Registered User
Tuning should not be to bad , has anyone thought of using the latest mk7 r ecu config if the current one cannt handle port injection as I know they come port and direct injection standard could be a oem way to get round it all
 

S3Alex

Rarely neutral
Gold Supporter
Tuning should not be to bad , has anyone thought of using the latest mk7 r ecu config if the current one cannt handle port injection as I know they come port and direct injection standard could be a oem way to get round it all

I think trying to fit a later model ECU is asking for trouble probably but thanks for the heads up on that.

What we will do is to use a standalone ECU mapped for boost,rpm,and temp as used by a friend of mine on his 700+bhp Golf.

That solution works and is relatively easy to implement without rewriting software and of course the Revo software would be incompatible.
 

S3Alex

Rarely neutral
Gold Supporter
would be wise im being told 550 is the most ill make with them injectors so ill be sourcing different injectors down the track.. tuning will always be an issue to be honest.., 8 injectors sounds complicated and you'll have more parts means more things prone to break... id hate to see the tuning side of things will be a challenge for sure....

That seems to be what some say.

Mine seems fine fuel wise at 500bhp and as we turn the boost up to 2.2bar or beyond AMD will be able to look at the AFR and there should be a bit to gain from the timing and cams.
 

jackj

Registered User
Really good read this mate - car's looking awesome
 

S3Alex

Rarely neutral
Gold Supporter
Really good read this mate - car's looking awesome

Thanks very much!

It's turning into a bit of a marathon read but everything that's been done,gone right or turned into a battle is all there.

If it encourages anyone or saves a few wrong turns along the way for someone then it's worthwhile and it's been a blast for me.
 

jackj

Registered User
It made for a good read with my cuppa this morning mate so keep it up!
 

S3Alex

Rarely neutral
Gold Supporter
It made for a good read with my cuppa this morning mate so keep it up!
Lol

Maybe a whole coffee pot.

Plenty more to follow after this round.

Also hoping to get a working diffuser and splitter if that project holds together.
 

S3Alex

Rarely neutral
Gold Supporter
Tuning should not be to bad , has anyone thought of using the latest mk7 r ecu config if the current one cannt handle port injection as I know they come port and direct injection standard could be a oem way to get round it all

This is looking like the most probable candidate for the injector ECU.



Comes with it's own software,allows mapping for load(TPS and MAP),rpm,temp,and battery voltage,plus it will only cut in when required,so it won't interfere,with the software already running,whereas any other solution requires a complete new software install,and neither Revo,nor APR would help(and indeed APR would only support their own hardware,i.e. the GTX2867,and I'm way beyond that).
 

Mesa

Registered User
Seriously, seriously impressed and inspired by this thread. Tons of massive info, should be pinned for anyone looking to get big power out their 8P.

I've not even read it properly yet but I'll be reading this start to end as it's so useful if you're looking at getting more than 360ish.

Top work.
 

S3Alex

Rarely neutral
Gold Supporter
Seriously, seriously impressed and inspired by this thread. Tons of massive info, should be pinned for anyone looking to get big power out their 8P.

I've not even read it properly yet but I'll be reading this start to end as it's so useful if you're looking at getting more than 360ish.

Top work.

Thank you....lots more to come,I hope!

It's due to guys here,and over on the sadly soon to close VAGOC,that I've been able to do this,plus the endless patience and technical abilities of AMDTuning.

I wanted to try and put back something into the forum,and maybe help a few of us put their money into the right places as we go.

The car is running again now after the latest pile of bits,and I'm waiting to see how it runs.
 

Mesa

Registered User
Gotta love these communities.

I've been guilty of using audi-sport as a reference for info without putting anything back. On of the reasons for starting my own thread. And whilst I won't get to the same levels as you it all adds to the richness of info for people to chew on and digest.

Good stuff....subbed.
 
Top